OWNER S MANUAL FJR1300N

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1 OWNER S MANUAL FJR1300N 5JW

2

3 EAU ĪNTRODUCTION Congratulations on your purchase of the Yamaha FJR1300. This model is the result of Yamaha s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields. This manual will give you an understanding of the operation, inspection, and basic maintenance of this motorcycle. If you have any questions concerning the operation or maintenance of your motorcycle, please consult a Yamaha dealer.

4 IMPORTANT MANUAL INFORMATION EAU00005 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING CAUTION: Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. NOTE: A NOTE provides key information to make procedures easier or clearer. NOTE: This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

5 IMPORTANT MANUAL INFORMATION EW WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

6 IMPORTANT MANUAL INFORMATION EAU03337 FJR1300N OWNER S MANUAL 2001 by Yamaha Motor Co., Ltd. 1st Edition, March 2001 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

7 EAU00009 TABLE OF CONTENTS 1 SAFETY INFORMATION 1 2 DESCRIPTION 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 4 PRE-OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX

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9 SAFETY INFORMATION Safe riding Protective apparel Modifications Loading and accessories Gasoline and exhaust gas Location of important labels

10 1-SAFETY INFORMATION EAU00014* 1 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DE- PENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BE- FORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. 2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANUAL. 3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES. 4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS. Safe riding 1. Always make pre-operation checks. Careful checks may help prevent an accident. 2. This motorcycle is designed to carry the operator and a passenger. 3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident. Therefore: a. Wear a brightly colored jacket. b. Use extra caution when you are approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur. c. Ride where other motorists can see you. Avoid riding in another motorist s blind spot. 1-1

11 SAFETY INFORMATION 4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators. b. Know your skills and limits. Staying within your limits may help you to avoid an accident. c. We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls. 5. Many accidents have been caused by error of the motorcycle operator. A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). a. Always obey the speed limit and never travel faster than warranted by road and traffic conditions. b. Always signal before turning or changing lanes. Make sure that other motorists can see you. 6. The posture of the operator and passenger is important for proper control. a. The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle. b. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with both hands and keep both feet on the passenger footrests. c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests. 7. Never ride under the influence of alcohol or other drugs. 8. This motorcycle is designed for on-road use only. It is not suitable for off-road use

12 SAFETY INFORMATION Protective apparel 1 The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries. 1. Always wear an approved helmet. 2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard. 3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations. 4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels and cause injury or an accident. 5. Never touch the engine or exhaust system during or after operation. They become very hot and can cause burns. Always wear protective clothing that covers your legs, ankles, and feet. 6. A passenger should also observe the above precautions. Modifications Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use. Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle: 1-3

13 SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 208 kg. When loading within this weight limit, keep the following in mind: 1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. 2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently. 3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such items as sleeping bags, duffel bags, or tents, can create unstable handling or a slow steering response. 1 Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-yamaha accessories. Use extreme caution when selecting and installing any accessories. Keep the following guidelines in mind, as well as those provided under Loading when mounting accessories. 1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or reflectors. 1-4

14 SAFETY INFORMATION 1 a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross winds. These accessories may also cause instability when passing or being passed by large vehicles. c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore, such accessories are not recommended. 2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the motorcycle s electrical system, an electric failure could result, which could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas 1. GASOLINE IS HIGHLY FLAMMABLE: a. Always turn the engine off when refueling. b. Take care not to spill any gasoline on the engine or exhaust system when refueling. c. Never refuel while smoking or in the vicinity of an open flame. 2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your motorcycle in an area that has adequate ventilation. 1-5

15 SAFETY INFORMATION 3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch. When parking the motorcycle, note the following: a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. c. Do not park the motorcycle near a flammable source (e.g., a kerosene heater, or near an open flame), otherwise it could catch fire. 4. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the fuel tank. 5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash the affected area with soap and water and change your clothes

16 1 SAFETY INFORMATION Location of important labels Please read the following important labels carefully before operating this motorcycle. EAU WARNING Before you operate this vehicle, read the owner s manual. English 3HP E0 2 4AA

17 DESCRIPTION Left view Right view Controls and instruments

18 2-DESCRIPTION EAU00026 Left view 2 1. Fuse box (page 6-30) 2. Front fork spring preload adjusting bolt (page 3-11) 3. Front fork rebound damping force adjusting knob (page 3-12) 4. Engine oil filler cap (page 6-10) 5. Owner s tool kit (page 6-1) 6. Rider seat (page 3-10) 7. Passenger seat (page 3-10) 8. Rear carrier 9. Final gear oil filler bolt (page 6-12) Final gear oil drain bolt (page 6-12) 11. Shock absorber assembly rebound damping force adjusting knob (page 3-14) 12. Shock absorber assembly spring preload adjusting lever (page 3-13) 13. Air filter element (page 6-15) 14. Shift pedal (page 3-6) 15. Engine oil filter cartridge (page 6-10) 16. Engine oil level check window (page 6-10)

19 DESCRIPTION Right view Passenger footrest 18. Coolant reservoir (page 6-13) 19. Battery (page 6-29) 20. Windshield 21. Main fuse and fuel injection system fuse (page 6-30) 22. Front fork compression damping force adjusting screw (page 3-12) 23. Brake pedal (page 3-7) 24. Rider footrest 2-2

20 DESCRIPTION Controls and instruments 2 1. Clutch lever (page 3-6) 2. Left handlebar switches (page 3-5) 3. Tachometer (page 3-3) 4. Speedometer (page 3-3) 5. Multi-function display (page 3-3) 6. Right handlebar switches (page 3-5) 7. Brake lever (page 3-7) 8. Throttle grip (page 6-17) 9. Main switch/steering lock (page 3-1) 2-3

21 INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock Indicator and warning lights Speedometer Tachometer Multi-function display Handlebar switches Clutch lever Shift pedal Brake lever Brake pedal Fuel tank cap Fuel Catalytic converter Seats Storage compartment Adjusting the front fork Adjusting the shock absorber assembly Matching the front and rear suspension settings Locks for the optional side cases and travel trunk Sidestand Ignition circuit cut-off system

22 3-INSTRUMENT AND CONTROL FUNCTIONS EAU EAU00029 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU00030 ON All electrical systems are supplied with power, and the headlight, meter lighting and taillight come on, and the engine can be started. The key cannot be removed. EAU00038 OFF All electrical systems are off. The key can be removed. 3-1 EAU00040 LOCK The steering is locked, and all electrical systems are off. The key can be removed. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the OFF position, and then turn it to LOCK while still pushing it. 3. Remove the key. To unlock the steering Push the key in, and then turn it to OFF while still pushing it. 1. Push. 2. Turn. EW WARNING Never turn the key to OFF or LOCK while the motorcycle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the motorcycle is stopped before turning the key to OFF or LOCK.

23 INSTRUMENT AND CONTROL FUNCTIONS 1. Left turn signal indicator light 2. Right turn signal indicator light 3. Neutral indicator light 4. High beam indicator light 5. Oil level warning light 6. Engine trouble warning light EAU03034 Indicator and warning lights EAU04121 Turn signal indicator lights and The corresponding indicator light flashes when the turn signal switch is pushed to the left or right. EAU00061 Neutral indicator light This indicator light comes on when the transmission is in the neutral position. EAU00063 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on. EAU03201 Oil level warning light This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked according to the following procedure. 1. Set the engine stop switch to and turn the key to ON. 2. Shift the transmission into the neutral position or pull the clutch lever. 3. Push the start switch. If the warning light does not come on while pushing the start switch, have a Yamaha dealer check the electrical circuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. EAU03192 Engine trouble warning light This warning light comes on or flashes when an electrical circuit monitoring the engine is defective. When this occurs, have the Yamaha dealer check the self-diagnosis system. The electrical circuit of the warning light can be checked according to the following procedure. 1. Set the engine stop switch to. 2. Turn the key to ON. If the warning light does not come on, have a Yamaha dealer check the electrical circuit

24 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Tachometer 2. Speedometer 3. Multi-function display EAU04031 Speedometer The speedometer shows the riding speed. 1. Tachometer 2. Tachometer red zone EAU00101 Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. EC CAUTION: Do not operate the engine in the tachometer red zone. Red zone: 9,000 r/min and above 1. Multi-function display 2. SELECT button 3. RESET button EAU04095 Multi-function display The multi-function display is equipped with the following: a fuel gauge a coolant temperature gauge an odometer (which shows the total distance traveled) two tripmeters (which show the distance traveled since they were last set to zero) a fuel reserve tripmeter (which shows the distance traveled on the fuel reserve) 3-3

25 INSTRUMENT AND CONTROL FUNCTIONS a selfdiagnosis device a clock Odometer and tripmeter modes Pushing the SELECT button switches the display between the odometer mode ODO and the tripmeter modes TRIP in the following order: ODO TRIP (top) TRIP (bottom) ODO When approximately 5 L of fuel remains in the fuel tank, the display will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance traveled from that point. In that case, pushing the SELECT button switches the display between the various tripmeter and odometer modes in the following order: TRIP F TRIP (top) TRIP (bottom) ODO TRIP F To reset a tripmeter, select it by pushing the SELECT button, and then push the RESET button for at least one second. If you do not reset the fuel reserve tripmeter manually, it will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km. Self-diagnosis device This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the clock will indicate a two-digit error code (e.g., 11, 12, 13). If the clock indicates such an error code, note the code number, and then have a Yamaha dealer check the motorcycle. ECA00100 CAUTION: If the clock indicates an error code, the motorcycle should be checked as soon as possible in order to avoid engine damage. Clock mode To set the clock: 1. Push the SELECT button and RESET button together for at least two seconds. 2. When the hour digits start flashing, push the RESET button to set the hours. 3. Push the SELECT button, and the minute digits will start flashing. 4. Push the RESET button to set the minutes. 5. Push the SELECT button and then release it to start the clock

26 INSTRUMENT AND CONTROL FUNCTIONS EAU04077 Windshield position adjusting switch To move the windshield up, push this switch in direction a. To move the windshield down, push the switch in direction b Pass switch 2. Windshield position adjusting switch 3. Dimmer switch / 4. Turn signal switch / 5. Horn switch Handlebar switches EAU00118 EAU00119 Pass switch Press this switch to flash the headlight. EAU03888 Dimmer switch / Set this switch to for the high beam and to for the low beam. NOTE: When the engine is turned off, the windshield will automatically return to the lowest position. EAU03889 Turn signal switch / To signal a right-hand turn, push this switch to. To signal a left-hand turn, push this switch to. When released, the switch returns to the center position. To cancel the turn signal lights, push the switch in after it has returned to the center position. EAU00129 Horn switch Press this switch to sound the horn. 1. Engine stop switch / 2. Start switch EAU03890 Engine stop switch / Set this switch to before starting the engine. Set this switch to to stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is stuck. EAU00143 Start switch Push this switch to crank the engine with the starter. EC CAUTION: See page 5-1 for starting instructions prior to starting the engine. 3-5

27 INSTRUMENT AND CONTROL FUNCTIONS EAU00153 Clutch lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. 1. Clutch lever 2. Arrow mark 3. Clutch lever position adjusting dial a. Distance between clutch lever and handlebar grip The clutch lever is equipped with a clutch lever position adjusting dial. To adjust the distance between the clutch lever and the handlebar grip, turn the adjusting dial while holding the lever pushed away from the handlebar grip. Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the clutch lever. The clutch lever is equipped with a clutch switch, which is part of the ignition circuit cut-off system. (See page 3-17 for an explanation of the ignition circuit cut-off system.) 1. Shift pedal EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle

28 INSTRUMENT AND CONTROL FUNCTIONS EAU00161 Brake lever The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handlebar grip Brake lever position adjusting dial 2. Arrow mark 3. Brake lever a. Distance between brake lever and handlebar grip The brake lever is equipped with a position adjusting dial. To adjust the distance between the brake lever and the handlebar grip, turn the adjusting dial while holding the lever pushed away from the handlebar grip. Make sure that the appropriate setting on the adjusting dial is aligned with the arrow mark on the brake lever. 1. Brake pedal EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 3-7

29 1. Fuel tank cap lock cover 2. Unlock. INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. EWA00025 WARNING Make sure that the fuel tank cap is properly closed before riding. 3 Fuel tank cap EAU04068 To open the fuel tank cap Open the fuel tank cap lock cover, insert the key into the lock, and then turn it 1/4 turn clockwise. The lock will be released and the fuel tank cap can be opened. To close the fuel tank cap 1. Push the fuel tank cap into position with the key inserted in the lock. 2. Remove the key, and then close the lock cover. 3-8

30 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Fuel tank filler tube 2. Fuel level EAU03753 Fuel Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown. EW WARNING Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. Avoid spilling fuel on the hot engine. EAU00185 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. Recommended fuel: Unleaded fuel only Fuel tank capacity: Total amount: 25 L Reserve amount: 5 L EAU00192* EAU01084 Catalytic converter This motorcycle is equipped with a catalytic converter in the exhaust chamber. EW WARNING The exhaust system is hot after operation. Make sure that the exhaust system has cooled down before doing any maintenance work. EC CAUTION: The following precautions must be observed to prevent a fire hazard or other damages. Use only unleaded gasoline. The use of leaded gasoline will cause unrepairable damage to the catalytic converter. Never park the motorcycle near possible fire hazards such as grass or other materials that easily burn. Do not allow the engine to idle too long. 3-9

31 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Rider seat lock 2. Unlock. Seats EAU03945 Rider seat To remove the rider seat 1. Insert the key into the seat lock, and then turn it as shown. 2. Pull the rider seat off. 1. Projection 2. Seat holder To install the rider seat 1. Insert the projection on the front of the rider seat into the seat holder as shown, and then push the rear of the seat down to lock it in place. 2. Remove the key. 1. Receptacle 2. Seat holder Passenger seat To remove the passenger seat 1. Remove the rider seat. 2. Pull the passenger seat up. To install the passenger seat 1. Slide the receptacle on the rear of the passenger seat over the seat holder as shown, and then push the front of the seat down. 2. Install the rider seat. NOTE: Make sure that the seats are properly secured before riding. 3-10

32 INSTRUMENT AND CONTROL FUNCTIONS EAU03949* Adjusting the front fork This front fork is equipped with spring preload adjusting bolts, rebound damping force adjusting knobs and compression damping force adjusting screws. EW EAU01242 Storage compartment The storage compartment is located under the passenger seat. (See page 3-10 for passenger seat opening and closing procedures.) EWA00005 WARNING Do not exceed the load limit of 3 kg for the storage compartment. Do not exceed the maximum load of 208 kg for the vehicle. WARNING Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. 1. Rebound damping force adjusting knob 2. Spring preload adjusting bolt Spring preload To increase the spring preload and thereby harden the suspension, turn the adjusting bolt on each fork leg in direction a. To decrease the spring preload and thereby soften the suspension, turn the adjusting bolt on each fork leg in direction b. 3-11

33 INSTRUMENT AND CONTROL FUNCTIONS 1. Current setting 2. Front fork cap bolt NOTE: Align the appropriate groove on the adjusting mechanism with the top of the front fork cap bolt. CI-01E Standard Hard Soft Setting Rebound damping force To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting knob on each fork leg in direction a. To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting knob on each fork leg in direction b. CI-09E Minimum (soft) 17 clicks in direction b* Standard 12 clicks in direction b* Maximum (hard) 1 click in direction b* * With the adjusting knob fully turned in direction a 1. Compression damping force adjusting screw Compression damping force To increase the compression damping force and thereby harden the compression damping, turn the adjusting screw on each fork leg in direction a. To decrease the compression damping force and thereby soften the compression damping, turn the adjusting screw on each fork leg in direction b. 3 CI-02E Minimum (soft) 21 clicks in direction b* Standard 12 clicks in direction b* Maximum (hard) 1 click in direction b* * With the adjusting screw fully turned in direction a 3-12

34 INSTRUMENT AND CONTROL FUNCTIONS 3 EC CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. NOTE: Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise adjustment, it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary. EAU03950 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjusting lever and a rebound damping force adjusting knob. EC CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. 1. Spring preload adjusting lever a. HARD b. SOFT Spring preload For riding solo, move the spring preload adjusting lever to SOFT. For riding with a passenger, move the spring preload adjusting lever to HARD. 3-13

35 1. Rebound damping force adjusting knob Rebound damping force To increase the rebound damping force and thereby harden the rebound damping, turn the adjusting knob in direction a. To decrease the rebound damping force and thereby soften the rebound damping, turn the adjusting knob in direction b. CI-09E Minimum (soft) 20 clicks in direction b* Standard 10 clicks in direction b* Maximum (hard) 3 clicks in direction b* * With the adjusting knob fully turned in direction a INSTRUMENT AND CONTROL FUNCTIONS EAU00315 WARNING This shock absorber contains highly pressurized nitrogen gas. For proper handling, read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. Do not tamper with or attempt to open the gas cylinder. Do not subject the shock absorber to an open flame or other high heat sources, otherwise it may explode due to excessive gas pressure. Do not deform or damage the gas cylinder in any way, as this will result in poor damping performance. Always have a Yamaha dealer service the shock absorber

36 INSTRUMENT AND CONTROL FUNCTIONS Matching the front and rear suspension settings Use this table as a guide to match the suspension and damping adjustments of the front fork and shock absorber assembly according to various load conditions. CI-11E Load condition Front fork adjustment Shock absorber assembly adjustment EAU Spring preload Compression damping force Rebound damping force Spring preload Rebound damping force Rider only SOFT 10 With passenger or cargo HARD 6-8 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. EC

37 INSTRUMENT AND CONTROL FUNCTIONS 1. Plastic bag containg locks EAU04043 Locks for the optional side cases and travel trunk There are three locks in a plastic bag located beside the owner s tool kit. When used to replace the locks of the optional side cases and travel trunk, which can be obtained at a Yamaha dealer, these locks can be operated with the ignition key. Keep these locks in a safe place to prevent losing them. EAU00330 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.) EW WARNING The motorcycle must not be ridden with the sidestand down, or if the sidestand cannot be properly moved up (or does not stay up), otherwise the sidestand could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha s ignition circuit cut-off system has been designed to assist the operator in fulfilling the responsibility of raising the sidestand before starting off. Therefore, check this system regularly as described below and have a Yamaha dealer repair it if it does not function properly

38 INSTRUMENT AND CONTROL FUNCTIONS 3 EAU03741 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled. It prevents starting when the transmission is in gear and the clutch lever is pulled, but the sidestand is still down. It cuts the running engine when the transmission is in gear and the sidestand is moved down. Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EW WARNING The vehicle must be placed on the centerstand during this inspection. If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-17

39 INSTRUMENT AND CONTROL FUNCTIONS CD-01E With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to. 3. Turn the key to ON. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled. 8. Shift the transmission into gear. 9. Move the sidestand down. Does the engine stall? YES After the engine has stalled: 10. Move the sidestand up. 11. Keep the clutch lever pulled. 12. Push the start switch. Does the engine start? YES NO NO NO The system is OK. The motorcycle can be ridden. NOTE: This check is most reliable if performed with a warmed-up engine. The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. The sidestand switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. The clutch switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer

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41 PRE-OPERATION CHECKS Pre-operation check list

42 4-PRE-OPERATION CHECKS EAU The condition of a vehicle is the owner s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride. CO-01E Fuel Pre-operation check list ITEM CHECKS PAGE Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage. Engine oil Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage Final gear oil Check vehicle for oil leakage Coolant Front brake Rear brake Check coolant level in reservoir. If necessary, add recommended coolant to specified level. Check cooling system for leakage. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage , EAU

43 PRE-OPERATION CHECKS Clutch Throttle grip Wheels and tires Brake and shift pedals Brake and clutch levers Centerstand, sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch ITEM CHECKS PAGE Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. Make sure that operation is smooth. Lubricate throttle grip, housing and cables if necessary. Check free play. If necessary, have Yamaha dealer make adjustment. Check for damage. Check tire condition and tread depth. Check air pressure. Correct if necessary. Make sure that operation is smooth. Lubricate pedal pivoting points if necessary. Make sure that operation is smooth. Lubricate lever pivoting points if necessary. Make sure that operation is smooth. Lubricate pivots if necessary. Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check operation. Correct if necessary. Check operation of ignition circuit cut-off system. If system is defective, have Yamaha dealer check vehicle. 6-20, ,

44 PRE-OPERATION CHECKS NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time; and the added safety it assures is more than worth the time involved. WARNING If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating the motorcycle. EWA

45 OPERATION AND IMPORTANT RIDING POINTS Starting and warming up a cold engine Shifting Tips for reducing fuel consumption Engine break-in Parking

46 5-OPERATION AND IMPORTANT RIDING POINTS EAU WARNING EAU00373 Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time. Always make sure that there is adequate ventilation. Before starting out, make sure that the sidestand is up. If the sidestand is not raised completely, it could contact the ground and distract the operator, resulting in a possible loss of control. EAU04096 Starting and warming up a cold engine In order for the ignition circuit cut-off system to enable starting, one of the following conditions must be met: The transmission is in the neutral position. The transmission is in gear with the clutch lever pulled and the sidestand up. EW WARNING Before starting the engine, check the function of the ignition circuit cut-off system according to the procedure described on page Never ride with the sidestand down. 1. Turn the key to ON and make sure that the engine stop switch is set to. ECA00083 CAUTION: The oil level warning light and engine trouble warning light should come on for a few seconds, then go off. If a warning light does not go off, see pages 3-2 and 3-3 for the corresponding warning light circuit check. 2. Shift the transmission into the neutral position. NOTE: When the transmission is in the neutral position, the neutral indicator light should be on, otherwise have a Yamaha dealer check the electrical circuit. 3. Start the engine by pushing the start switch. 5-1

47 OPERATION AND IMPORTANT RIDING POINTS NOTE: If the engine fails to start, release the start switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. ECA00045 CAUTION: For maximum engine life, never accelerate hard when the engine is cold! NOTE: The engine is warm when it quickly responds to the throttle. 1. Shift pedal N. Neutral position EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. EC CAUTION: Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances. The transmission is properly lubricated only when the engine is running. Inadequate lubrication may damage the transmission. Always use the clutch while changing gears to avoid damaging the engine, transmission, and drive train, which are not designed to withstand the shock of forced shifting. 5 NOTE: To shift the transmission into the neutral position, press the shift pedal down repeatedly until it reaches the end of its travel, and then slightly raise it. 5-2

48 OPERATION AND IMPORTANT RIDING POINTS 5 EAU03952 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: Thoroughly warm up the engine. Shift up swiftly, and avoid high engine speeds during acceleration. Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine. Turn the engine off instead of letting it idle for an extended length of time (e.g., in traffic jams, at traffic lights or at railroad crossings). EAU01128 Engine break-in There is never a more important period in the life of your engine than the period between 0 and 1,600 km. For this reason, you should read the following material carefully. Since the engine is brand new, do not put an excessive load on it for the first 1,600 km. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full-throttle operation or any condition that might result in engine overheating must be avoided. EAU04032* 0 1,000 km Avoid prolonged operation above 5,000 r/min. 1,000 1,600 km Avoid prolonged operation above 6,000 r/min. EC000056* CAUTION: After 1,000 km of operation, the engine oil and final gear oil must be changed, and the oil filter cartridge replaced. 1,600 km and beyond The vehicle can now be operated normally. EC CAUTION: Keep the engine speed out of the tachometer red zone. If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. 5-3

49 OPERATION AND IMPORTANT RIDING POINTS EAU00461 Parking When parking, stop the engine, and then remove the key from the main switch. EW WARNING Since the engine and exhaust system can become very hot, park in a place where pedestrians or children are not likely to touch them. Do not park on a slope or on soft ground, otherwise the motorcycle may overturn. 5 EC CAUTION: Never park in an area where there are fire hazards such as grass or other flammable materials. 5-4

50

51 PERIODIC MAINTENANCE AND MINOR REPAIR Owner s tool kit Periodic maintenance and lubrication chart Removing and installing the cowling and panels Checking the spark plugs Engine oil and oil filter cartridge Final gear oil Checking the coolant level Cleaning the air filter element Checking the engine idling speed Adjusting the throttle cable free play Adjusting the valve clearance Tires Cast wheels Clutch lever free play Adjusting the brake lever free play Adjusting the brake pedal position Adjusting the rear brake light switch Checking the front and rear brake pads Checking the brake and clutch fluid levels Changing the brake and clutch fluids Checking and lubricating the cables Checking and lubricating the throttle grip and cable Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers Checking and lubricating the centerstand and sidestand Lubricating the rear suspension Checking the front fork Checking the steering Checking the wheel bearings Battery Replacing the fuses Replacing a headlight bulb Replacing a tail/brake light bulb Replacing a turn signal light bulb Troubleshooting Troubleshooting charts

52 6-PERIODIC MAINTENANCE AND MINOR REPAIR EAU EAU00464 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages. The intervals given in the periodic maintenance and lubrication chart should be simply considered as a general guide under normal riding conditions. However, DEPENDING ON THE WEATHER, TERRAIN, GEOGRAPHI- CAL LOCATION, AND INDIVIDUAL USE, THE MAINTENANCE INTER- VALS MAY NEED TO BE SHORT- ENED. EW WARNING If you are not familiar with motorcycle maintenance work, have a Yamaha dealer do it for you. 1. Owner s tool kit EAU03711 Owner s tool kit The owner s tool kit is located under the rider seat. (See page 3-10 for rider seat removal and installation procedures.) The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However, additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you. EW WARNING Modifications not approved by Yamaha may cause loss of performance and render the vehicle unsafe for use. Consult a Yamaha dealer before attempting any changes. 6-1

53 PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance and lubrication chart EAU03685 NOTE: The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. CP-03E ODOMETER READING ( 1,000 km) ANNUAL NO. ITEM CHECK OR MAINTENANCE JOB CHECK 1 * Fuel line Check fuel hoses for cracks or damage. Check condition. 2 Spark plugs Clean and regap. Replace. 3 * Valves Check valve clearance. Every 40,000 km Adjust. Clean. 4 Air filter element Replace. 5 * Clutch Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.) 6 * Front brake (See NOTE on page 6-4.) Check operation, fluid level and vehicle for fluid leakage. Replace brake pads. 7 * Rear brake (See NOTE on page 6-4.) Check operation, fluid level and vehicle for fluid leakage. Replace brake pads. Whenever worn to the limit Whenever worn to the limit 6 6-2

54 PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM CHECK OR MAINTENANCE JOB ODOMETER READING ( 1,000 km) * Brake hoses Check for cracks or damage. Replace. (See NOTE on page 6-4.) Every 4 years ANNUAL CHECK 9 * Wheels Check runout and for damage. Check tread depth and for damage. 10 * Tires Replace if necessary. Check air pressure. Correct if necessary. 11 * Wheel bearings Check bearing for looseness or damage. 12 * Swingarm Operation and for excessive play. Lubricate with lithium-soap-based grease. Every 50,000 km 6 13 * Steering bearings Check bearing play and steering for roughness. Lubricate with lithium-soap-based grease. Every 20,000 km 14 * Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. 15 Sidestand/centerstand Check operation. Lubricate. 16 * 17 * Sidestand switch Check operation. Front fork Check operation and for oil leakage. 18 * 19 * 20 * Shock absorber assembly Rear suspension relay arm and connecting arm pivoting points Electronic fuel injection system Check operation and shock absorber for oil leakage. Check operation. Lubricate with lithium-soap-based grease. Adjust engine idling speed and synchronization. 21 Engine oil Change. 6-3

55 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING ( 1,000 km) ANNUAL NO. ITEM CHECK OR MAINTENANCE JOB CHECK 22 Engine oil filter cartridge Replace. 23 * Cooling system Check coolant level and vehicle for coolant leakage. Change. Every 3 years Check oil level and vehicle for oil leakage. 24 Final gear oil Change. 25 * Muffler and exhaust pipe Check the screw clamp for looseness. Front and rear brake 26 * Check operation. switches 27 Moving parts and cables Lubricate. 28 * Lights, signals and switches Check operation. Adjust headlight beam. NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake and clutch systems After disassembling the brake or clutch master cylinders, caliper cylinders or clutch release cylinder, always change the fluid. Regularly check the brake and clutch fluid levels and fill the reservoirs as required. Replace the oil seals on the inner parts of the brake or clutch master cylinders, caliper cylinders and clutch release cylinder every two years. Replace the brake and clutch hoses every four years or if cracked or damaged. EAU

56 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1. Cowling A 1. Panel A 2. Panel B 3. Panel C 4. Panel D EAU03516 Removing and installing the cowling and panels The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed. 1. Panel E 6-5

57 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Panel F 1. Screw ( 9) 2. Quick fastener screw EAU03536 Cowling A To remove the cowling Remove the screw, loosen the quick fastener screws 1/4 turn counterclockwise, and then take the cowling off. To install the cowling Place the cowling in the original position, and then tighten the quick fastener screws and install the screw. 1. Screw ( 3) 2. Quick fastener screw ( 2) EAU04061 Panel A To remove the panel Remove the screws and the quick fastener screws, and then take the panel off. To install the panel Place the panel in the original position, and then install the screws and the quick fastener screws

58 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1. Screw ( 2) 2. Quick fastener screw EAU04062 Panels B and C To remove one of the panels 1. Remove panel A (if removing panel B) or panel D (if removing panel C). 2. Loosen the quick fastener screw and remove the screws, and then take the panel off. 1. Screw ( 2) 2. Quick fastener screw To install the panel 1. Place the panel in the original position, and then tighten the quick fastener screw and install the screws. 2. Install panel A (to complete the installation of panel B) or panel D (to complete the installation of panel C). 1. Screw ( 3) EAU01315 Panel D To remove the panel Remove the screws, and then take the panel off. To install the panel Place the panel in the original position, and then install the screws. 6-7

59 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw ( 2) 2. Quick fastener screw ( 2) 3. Quick fastener ( 2) EAU04063 Panels E and F To remove one of the panels 1. Remove the seats. (See page 3-10 for seat removal and installation procedures.) 2. Remove the screws, the quick fastener screws and the quick fasteners, and then take the panel off. To install the panel 1. Place the panel in the original position, and then install the quick fasteners and quick fastener screws, and tighten the screws. 2. Install the seats. EAU01880 Checking the spark plugs The spark plugs are important engine components, which should be checked periodically, preferably by a Yamaha dealer. Since heat and deposits will cause any spark plug to slowly erode, they should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine. The porcelain insulator around the center electrode of each spark plug should be a medium-to-light tan (the ideal color when the motorcycle is ridden normally), and all spark plugs installed in the engine should have the same color. If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the motorcycle. If a spark plug shows signs of electrode erosion and excessive carbon or other deposits, it should be replaced. 6-8 Specified spark plug: CR8E (NGK) or U24ESR-N (DENSO) 6

60 PERIODIC MAINTENANCE AND MINOR REPAIR 6 a. Spark plug gap Before installing a spark plug, the spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specification. Spark plug gap: mm Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from the spark plug threads. Tightening torque: Spark plug: 12.5 Nm (1.25 m kgf) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4 1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. EAU03997 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the motorcycle on the centerstand. NOTE: Make sure that the motorcycle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. 2. Start the engine, warm it up for several minutes, and then turn it off. 6-9

61 PERIODIC MAINTENANCE AND MINOR REPAIR 4. Remove the oil filter cartridge with an oil filter wrench. NOTE: An oil filter wrench is available at a Yamaha dealer. 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 3. Wait a few minutes until the oil settles, and then check the oil level through the check window located at the bottom-left side of the crankcase. NOTE: The engine oil should be between the minimum and maximum level marks. 4. If the engine oil is below the minimum level mark, add sufficient oil of the recommended type to raise it to the correct level. 1. Engine oil filler cap 2. Engine oil filter cartridge 3. Engine oil drain bolt To change the engine oil (with or without oil filter cartridge replacement) 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. NOTE: Skip steps 4 6 if the oil filter cartridge is not being replaced. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. NOTE: Make sure that the O-ring is properly seated. 6. Install the new oil filter cartridge, and then tighten it to the specified torque with a torque wrench. Tightening torque: Oil filter cartridge: 17 Nm (1.7 m kgf) 7. Install the engine oil drain bolt, and then tighten it to the specified torque

62 PERIODIC MAINTENANCE AND MINOR REPAIR 6 Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m kgf) 8. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 3.8 L With oil filter cartridge replacement: 4 L Total amount (dry engine): 4.9 L EC CAUTION: In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives with the oil or use oils of a higher grade than CD. In addition, do not use oils labeled ENERGY CONSERVING II or higher. Make sure that no foreign material enters the crankcase. 9. Start the engine, and then let it idle for several minutes while checking it for oil leakage. If oil is leaking, immediately turn the engine off and check for the cause. NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient. EC CAUTION: If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle. 10. Turn the engine off, and then check the oil level and correct it if necessary. 6-11

63 PERIODIC MAINTENANCE AND MINOR REPAIR EAU04067 Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha dealer check and repair the motorcycle. In addition, the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart. EW WARNING Make sure that no foreign material enters the final gear case. Make sure that no oil gets on the tire or wheel. 1. Final gear oil filler bolt 2. Final gear oil drain bolt 3. Correct oil level To check the final gear oil level 1. Place the motorcycle on the centerstand. NOTE: The final gear oil level must be checked on a cold engine. Make sure that the motorcycle is positioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole. 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. To change the final gear oil 1. Place an oil pan under the final gear case to collect the used oil. 2. Remove the oil filler bolt and drain bolt to drain the oil from the final gear case. 3. Install the final gear oil drain bolt, and then tighten it to the specified torque. Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m kgf) 4. Add the recommended final gear oil to the brim of the filler hole

64 PERIODIC MAINTENANCE AND MINOR REPAIR 6 Recommended final gear oil: Shaft drive gear oil (Part No.: 9079E-SH001-00) Oil quantity: 0.2 L 5. Install and tighten the filler bolt. 6. Check the final gear case for oil leakage. If oil is leaking, check for the cause. EAU04044 Checking the coolant level The coolant level should be checked as follows before each ride. In addition, the coolant must be changed at the intervals specified in the periodic maintenance and lubrication chart. 1. Place the motorcycle on a level surface and hold it in an upright position. NOTE: The coolant level must be checked on a cold engine since the level varies with engine temperature. Make sure that the motorcycle is positioned straight up when checking the coolant level. A slight tilt to the side can result in a false reading. 1. Maximum level mark 2. Minimum level mark 2. Check the coolant level in the coolant reservoir. NOTE: The coolant should be between the minimum and maximum level marks. 6-13

65 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw 2. Reservoir cap cover 3. Reservoir cap 3. If the coolant is at or below the minimum level mark, remove cowling A (See page 6-6 for cowling removal and installation procedures.), open the reservoir cap, add coolant to the maximum level mark, close the reservoir cap, and then install the cowling. EC CAUTION: If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion. If water has been added to the coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. NOTE: The radiator fan is automatically switched on or off according to the coolant temperature in the radiator. If the engine overheats, see page 6-35 for further instructions. 6 Coolant reservoir capacity: 0.25 L EW WARNING Never attempt to remove the radiator cap when the engine is hot. 6-14

66 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1. Air shroud 2. Quick fastener ( 4) EAU03998* Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1. Remove panel E. (See page 6-8 for panel removal and installation procedures.) 2. Remove the intake air shroud by removing the quick fasteners. 1. Air filter case cover 2. Screw ( 4) 3. Remove the air filter case cover by removing the screws. 1. Air filter element 4. Pull the air filter element out. 6-15

67 PERIODIC MAINTENANCE AND MINOR REPAIR 5. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air as shown. If the air filter element is damaged, replace it. 6. Insert the air filter element into the air filter case. EC000082* CAUTION: Make sure that the air filter element is properly seated in the air filter case. The engine should never be operated without the air filter element installed, otherwise the pistons and/or cylinders may become excessively worn. 7. Install the air filter case cover by installing the screws. 8. Install the intake air shroud by installing the quick fasteners. 9. Install the panel. EAU04033 Checking the engine idling speed The engine idling speed must be checked as follows and, if necessary, adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. Start the engine and warm it up for several minutes at 1,000 2,000 r/min while occasionally revving it to 4,000 5,000 r/min. NOTE: The engine is warm when it quickly responds to the throttle. Engine idling speed: 1,000 1,100 r/min

68 PERIODIC MAINTENANCE AND MINOR REPAIR 6 a. Throttle cable free play EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm at the throttle grip. Periodically check the throttle cable free play and, if necessary, have a Yamaha dealer adjust it. EAU00637 Adjusting the valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. EAU03296 Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EW WARNING The tire air pressure must be checked and adjusted on cold tires (i.e., when the temperature of the tires equals the ambient temperature). The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider, passenger, cargo, and accessories approved for this model. 6-17

69 PERIODIC MAINTENANCE AND MINOR REPAIR CE-01E Tire air pressure (measured on cold tires) Load* Front Rear Up to 90 kg 90 kg maximum High-speed riding 250 kpa (2.50 kgf/cm 2, 2.50 bar) 250 kpa (2.50 kgf/cm 2, 2.50 bar) 250 kpa (2.50 kgf/cm 2, 2.50 bar) CE-07E Maximum load* 208 kg * Total weight of rider, passenger, cargo and accessories 250 kpa (2.50 kgf/cm 2, 2.50 bar) 290 kpa (2.90 kgf/cm 2, 2.90 bar) 290 kpa (2.90 kgf/cm 2, 2.90 bar) EW WARNING Proper loading of your motorcycle is important for several characteristics of your motorcycle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR MOTOR- CYCLE. Make sure that the total weight of the cargo, rider, passenger, and accessories (cowling, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury. 1. Tire sidewall 2. Tire wear indicator a. Tire tread depth Tire inspection Always check the tires before operating the motorcycle. If a tire tread shows crosswise lines (minimum tread depth), if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced

70 PERIODIC MAINTENANCE AND MINOR REPAIR 6 WARNING EW Have a Yamaha dealer replace excessively worn tires. Besides being illegal, operating the motorcycle with excessively worn tires decreases riding stability and can lead to loss of control. The replacement of all wheeland brake-related parts, including the tires, should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. CE-20E Minimum tire tread depth (front and rear) NOTE: The tire tread depth limits may differ from country to country. Always comply with the local regulations. 1.0 mm 1. Tire air valve 2. Tire air valve core 3. Tire air valve cap with seal Tire information This motorcycle is equipped with cast wheels and tubeless tires with valves. EW WARNING The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd. Always make sure that the valve caps are securely installed to prevent air pressure leakage. Use only the tire valves and valve cores listed below to avoid tire deflation during a high-speed ride. CE-10E FRONT Manufacturer Size Model Metzeler 120/70 ZR17 (58W) MEZ4B FRONT Bridgestone 120/70 ZR17 (58W) BT020FN REAR Manufacturer Size Model Metzeler 180/55 ZR17 (73W) MEZ4J Bridgestone 180/55 ZR17 (73W) BT020RN CE-14E FRONT & REAR Tire air valve TR412 Valve core #9000A (original) 6-19

71 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00684 WARNING This motorcycle is fitted with superhigh-speed tires. Note the following points in order to make the most efficient use of these tires. Use only the specified replacement tires. Other tires may run the danger of bursting at super high speeds. Brand-new tires can have a relatively poor grip on certain road surfaces until they have been broken in. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km after installing a new tire. The tires must be warmed up before a high-speed run. Always adjust the tire air pressure according to the operating conditions. EAU03773 Cast wheels To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified wheels. The wheel rims should be checked for cracks, bends or warpage before each ride. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A deformed or cracked wheel must be replaced. The wheel should be balanced whenever either the tire or wheel has been changed or replaced. An unbalanced wheel can result in poor performance, adverse handling characteristics, and a shortened tire life. Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics. EAU00695 Clutch lever free play Since this model is equipped with a hydraulic clutch, adjusting the clutch lever free play is not needed. However, it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride. If the clutch lever free play does become excessive, and shifting becomes rough or clutch slippage occurs, causing poor acceleration, there may be air in the clutch system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle

72 6 PERIODIC MAINTENANCE AND MINOR REPAIR a. Brake lever free play a. Distance between brake pedal and footrest EAU00697 Adjusting the brake lever free play The brake lever free play should measure 3 11 mm as shown. Periodically check the brake lever free play and, if necessary, have a Yamaha dealer adjust it. EW WARNING An incorrect brake lever free play indicates a hazardous condition in the brake system. Do not operate the motorcycle until the brake system has been checked or repaired by a Yamaha dealer. EAU00712 Adjusting the brake pedal position The top of the brake pedal should be positioned approximately 40 mm below the top of the footrest as shown. Periodically check the brake pedal position and, if necessary, have a Yamaha dealer adjust it. EW WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle. Air in the hydraulic system will diminish the braking performance, which may result in loss of control and an accident. 6-21

73 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00721 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 1. Rear brake light switch 2. Rear brake light switch adjusting nut EAU00713 Adjusting the rear brake light switch The rear brake light switch, which is activated by the brake pedal, is properly adjusted when the brake light comes on just before braking takes effect. If necessary, adjust the brake light switch as follows. Turn the adjusting nut while holding the rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a. To make the brake light come on later, turn the adjusting nut in direction b. 1. Brake pad wear indicator groove ( 2) EAU00725 Front brake pads Each front brake pad is provided with a wear indicator groove, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set

74 PERIODIC MAINTENANCE AND MINOR REPAIR Front brake Rear brake 6 1. Brake pad wear indicator 1. Minimum level mark EAU00728 Rear brake pads Each rear brake pad is provided with a wear indicator, which allows you to check the brake pad wear without having to disassemble the brake. To check the brake pad wear, check the position of the wear indicator while applying the brake. If a brake pad has worn to the point that the wear indicator almost touches the brake disc, have a Yamaha dealer replace the brake pads as a set. EAU04098 Checking the brake and clutch fluid levels Insufficient brake fluid may allow air to enter the brake or clutch systems, possibly causing them to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn brake pads and/or brake system leakage. If the brake level is low, be sure to check the brake pads for wear and the brake system for leakage. NOTE: The rear brake fluid reservoir is located behind panel F. (See page 6-8 for panel removal and installation procedures.) Minimum level mark Observe these precautions: When checking the fluid level, make sure that the top of the brake or clutch fluid reservoir is level. Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking or clutch performance. Recommended brake and clutch fluid: DOT 4 brake fluid Refill with the same type of brake fluid. Mixing fluids may result in a harmful chemical reaction and lead to poor braking or clutch performance.

75 PERIODIC MAINTENANCE AND MINOR REPAIR Clutch 1. Minimum level mark Be careful that water does not enter the brake or clutch fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause. EAU03984 Changing the brake and clutch fluids Have a Yamaha dealer change the brake and clutch fluids at the intervals specified in the NOTE after the periodic maintenance and lubrication chart. In addition, have the oil seals of the brake and clutch master cylinders and calipers as well as the brake and clutch hoses replaced at the intervals listed below or whenever they are damaged or leaking. Oil seals: Replace every two years. Brake and clutch hoses: Replace every four years. EAU02962 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it. EW WARNING Damage to the outer sheath may interfere with proper cable operation and will cause the inner cable to rust. Replace a damaged cable as soon as possible to prevent unsafe conditions. Recommended lubricant: Engine oil

76 PERIODIC MAINTENANCE AND MINOR REPAIR EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart. 6 EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-25

77 PERIODIC MAINTENANCE AND MINOR REPAIR Recommended lubricant: Lithium-soap-based grease (all-purpose grease) EAU03371 Checking and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary. EW WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. EAU03166 Lubricating the rear suspension The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Lithium-soap-based grease (all-purpose grease)

78 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. To check the condition EW WARNING Securely support the motorcycle so that there is no danger of it falling over. Check the inner tubes for scratches, damage and excessive oil leakage. To check the operation 1. Place the motorcycle on a level surface and hold it in an upright position. 2. While applying the front brake, push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly. EAU00794 Checking the steering Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1. Place a stand under the engine to raise the front wheel off the ground. EW WARNING Securely support the motorcycle so that there is no danger of it falling over. EC CAUTION: If any damage is found or the front fork does not operate smoothly, have a Yamaha dealer check or repair it. 6-27

79 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering

80 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1. Battery EAU04035 Battery The battery is located under panel D. (See page 6-7 for panel removal and installation procedures.) This motorcycle is equipped with a sealed-type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add distilled water. To charge the battery Have a Yamaha dealer charge the battery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the motorcycle is equipped with optional electrical accessories EW WARNING Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. EXTERNAL: Flush with plenty of water. INTERNAL: Drink large quantities of water or milk and immediately call a physician. EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. KEEP THIS AND ALL BATTER- IES OUT OF THE REACH OF CHILDREN. To store the battery 1. If the motorcycle will not be used for more than one month, remove the battery, fully charge it, and then place it in a cool, dry place. 2. If the battery will be stored for more than two months, check it at least once a month and fully charge it if necessary. 3. Fully charge the battery before installation.

81 PERIODIC MAINTENANCE AND MINOR REPAIR EC CAUTION: Always keep the battery charged. Storing a discharged battery can cause permanent battery damage. To charge a sealed-type (MF) battery, a special (constantvoltage) battery charger is required. Using a conventional battery charger will damage the battery. If you do not have access to a sealed-type (MF) battery charger, have a Yamaha dealer charge your battery. 1. Fuel injection system fuse 2. Spare fuel injection system fuse EAU04076* Replacing the fuses The fuse box, which contains the fuses for the individual circuits, is located under panel D. The fuel injection system fuse box is located under panel D. The main fuse box is also located under panel D, beside the battery. (See page 6-7 for panel removal and installation procedures.) If a fuse is blown, replace it as follows. 1. Turn the key to OFF and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. 1. Headlight fuse 2. Signaling system fuse 3. Ignition fuse 4. Windshield motor fuse 5. Radiator fan fuse 6. Backup fuse (odometer and clock) 7. Spare fuse ( 4)

82 PERIODIC MAINTENANCE AND MINOR REPAIR EC CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire Main fuse Specified fuses: Main fuse: 50 A Headlight fuse: 25 A Signaling system fuse: 15 A Ignition fuse: 10 A Windshield motor fuse: 2 A Radiator fan fuse: 15 A Backup fuse (odometer and clock): 10 A Fuel injection system fuse: 15 A 3. Turn the key to ON and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Headlight coupler 2. Headlight bulb cover EAU04099 Replacing a headlight bulb This motorcycle is equipped with quartz bulb headlights. If a headlight bulb burns out, replace it as follows. 1. Remove panel B (if replacing the left headlight bulb) or panel C (if replacing the right headlight bulb). (See page 6-7 for panel removal and installation procedures.) 2. Disconnect the headlight coupler, and then remove the headlight bulb cover. 6-31

83 PERIODIC MAINTENANCE AND MINOR REPAIR 4. Place a new bulb into position, and then secure it with the bulb holder EC CAUTION: Take care not to damage the following parts: Headlight bulb Do not touch the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the luminosity 1. Headlight bulb holder of the bulb, and the bulb life 1. Socket 3. Unhook the headlight bulb holder, and then remove the defective bulb. will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb EW using a cloth moistened with alcohol WARNING or thinner. Headlight bulbs get very hot. Therefore, keep flammable products away Headlight lens Do not affix any type of tinted film or stickers to the headlight lens. from a lit headlight bulb, and do not touch the bulb until it has cooled Do not use a headlight bulb of down. a wattage higher than specified. 5. Install the bulb cover, and then connect the coupler. 6. Install the panel. 7. Have a Yamaha dealer adjust the headlight beam if necessary. EAU04000 Replacing a tail/brake light bulb 1. Remove the passenger seat. (See page 3-10 for passenger seat removal and installation procedures.) 2. Remove the socket (together with the bulb) by turning it counterclockwise. 3. Remove the defective bulb by turning it counterclockwise. 4. Insert a new bulb into the socket, and then turn it clockwise until it stops. 5. Install the socket (together with the bulb) by turning it clockwise. 6. Install the passenger seat. 6

84 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1. Screw EAU03497 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screw. ECA00065 CAUTION: Do not overtighten the screw, otherwise the lens may break EAU03087 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubleshooting charts represent quick and easy procedures for checking these vital systems yourself. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly. Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they are often inferior, have a shorter service life and can lead to expensive repair bills.

85 PERIODIC MAINTENANCE AND MINOR REPAIR Troubleshooting charts Starting problems or poor engine performance EAU02990 EW WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel Check the fuel level in the fuel tank. There is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the compression. 2. Compression There is compression. Check the ignition. Operate the electric starter. There is no compression. Have a Yamaha dealer check the vehicle Ignition Wipe off with a dry cloth and correct the Remove the spark plugs and check the electrodes. Wet Dry spark plug gaps, or replace the spark plugs. Have a Yamaha dealer check the vehicle. Open the throttle halfway and operate the electric starter. The engine does not start. Check the battery. 4. Battery Operate the electric starter. The engine turns over quickly. The engine turns over slowly. The battery is good. Check the battery lead connections, and charge the battery if necessary. The engine does not start. Have a Yamaha dealer check the vehicle. 6-34

86 PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled. After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap. EW Wait until the engine has cooled. Check the coolant level in the reservoir and radiator. The coolant level is low. Check the cooling system for leakage. There is leakage. There is no leakage. Have a Yamaha dealer check and repair the cooling system. Add coolant. (See NOTE.) The coolant level is OK. Start the engine. If the engine overheats again, have a Yamaha dealer check and repair the cooling system. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible. 6-35

87 MOTORCYCLE CARE AND STORAGE Care Storage

88 7-MOTORCYCLE CARE AND STORAGE EAU Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle. Frequent and proper care does not only comply with the terms of the warranty, but it will also keep your motorcycle looking good, extend its life and optimize its performance. Before cleaning 1. Cover the muffler outlets with plastic bags after the engine has cooled down. 2. Make sure that all caps and covers as well as all electrical couplers and connectors, including the spark plug caps, are tightly installed. 3. Remove extremely stubborn dirt, like oil burnt onto the crankcase, with a degreasing agent and a brush, but never apply such products onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water. Cleaning ECA00010 CAUTION: Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such products are used on hard-to-remove dirt, do not leave the cleaner on the affected area any longer than instructed. Also, thoroughly rinse the area off with water, immediately dry it, and then apply a corrosion protection spray. Improper cleaning can damage windshields, cowlings, panels and other plastic parts. Use only a soft, clean cloth or sponge with mild detergent and water to clean plastic. 7-1

89 MOTORCYCLE CARE AND STORAGE Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte. Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration in the following areas: seals (of wheel and swingarm bearings, fork and brakes), electric components (couplers, connectors, instruments, switches and lights), breather hoses and vents. For motorcycles equipped with a windshield: Do not use strong cleaners or hard sponges as they will cause dulling or scratching. Some cleaning compounds for plastic may leave scratches on the windshield. Test the product on a small hidden part of the windshield to make sure that it does not leave any marks. If the windshield is scratched, use a quality plastic polishing compound after washing. After normal use Remove dirt with warm water, a mild detergent, and a soft, clean sponge, and then rinse thoroughly with clean water. Use a toothbrush or bottlebrush for hard-to-reach areas. Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning. After riding in the rain, near the sea or on salt-sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water, carry out the following steps after each ride in the rain, near the sea or on salt-sprayed roads. NOTE: Salt sprayed on roads in the winter may remain well into spring. 1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled down. ECA00012 CAUTION: Do not use warm water since it increases the corrosive action of the salt. 2. After drying the motorcycle, apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces to prevent corrosion

90 MOTORCYCLE CARE AND STORAGE 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal, including chrome- and nickel-plated, surfaces. 4. Use spray oil as a universal cleaner to remove any remaining dirt. 5. Touch up minor paint damage caused by stones, etc. 6. Wax all painted surfaces. 7. Let the motorcycle dry completely before storing or covering it. EWA00031 WARNING Make sure that there is no oil or wax on the brakes or tires. If necessary, clean the brake discs and brake linings with a regular brake disc cleaner or acetone, and wash the tires with warm water and a mild detergent. Before riding at higher speeds, test the motorcycle s braking performance and cornering behavior. ECA00013 CAUTION: Apply spray oil and wax sparingly and make sure to wipe off any excess. Never apply oil or wax to any rubber and plastic parts, but treat them with a suitable care product. Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. 7-3

91 MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA00014 CAUTION: Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust. To prevent corrosion, avoid damp cellars, stables (because of the presence of ammonia) and areas where strong chemicals are stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in the Care section of this chapter. 2. For motorcycles equipped with a fuel cock that has an OFF position: Turn the fuel cock lever to OFF. 3. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 4. Perform the following steps to protect the cylinders, piston rings, etc. from corrosion. a. Remove the spark plug caps and spark plugs. b. Pour a teaspoonful of engine oil into each spark plug bore. c. Install the spark plug caps onto the spark plugs, and then place the spark plugs on the cylinder head so that the electrodes are grounded. (This will limit sparking during the next step.) d. Turn the engine over several times with the starter. (This will coat the cylinder walls with oil.) e. Remove the spark plug caps from the spark plugs, and then install the spark plugs and the spark plug caps. EWA00003 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over

92 MOTORCYCLE CARE AND STORAGE 7 5. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 6. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 7. Cover the muffler outlets with plastic bags to prevent moisture from entering them. 8. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a month. Do not store the battery in an excessively cold or warm place (less than 0 C or more than 30 C). For more information on storing the battery, see page NOTE: Make any necessary repairs before storing the motorcycle. 7-5

93 SPECIFICATIONS Specifications Conversion table

94 8-SPECIFICATIONS EAU Specifications CS-01E Model FJR1300 Dimensions Overall length 2,195 mm Overall width 760 mm Overall height 1,420 mm Seat height 805 mm Wheelbase 1,515 mm Ground clearance 135 mm Minimum turning radius 3,100 mm Basic weight (with oil and full fuel tank) 268 kg Engine Engine type Liquid-cooled 4-stroke, DOHC Cylinder arrangement Forward-inclined parallel 4-cylinder Displacement 1,298 cm 3 Bore stroke mm Compression ratio 10.8:1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification Quantity Without oil filter cartridge replacement With oil filter cartridge replacement Total amount (dry engine) C API Service SE, SF, SG or higher 3.8 L 4 L 4.9 L SAE 10W-40 SAE 15W-40 SAE 20W-40 CAUTION: Be sure to use motor oils that do not contain anti-friction modifiers. Passenger car motor oils (often labeled ENERGY CONSERVING II ) contain anti-friction additives which will cause clutch and/or starter clutch slippage, resulting in reduced component life and poor engine performance. 8-1

95 SPECIFICATIONS Final gear oil Type Quantity Cooling system capacity (total amount) Air filter Fuel Type Fuel tank capacity Fuel reserve amount Spark plug Manufacturer/model Shaft drive gear oil (Part No.: 9079E-SH001-00) 0.2 L 3.3 L Dry type element Unleaded fuel only 25 L 5 L NGK / CR8E or DENSO / U24ESR-N mm Gap Clutch type Wet, multiple-disc Transmission Primary reduction system Helical gear Primary reduction ratio Secondary reduction system Shaft drive Secondary reduction ratio Transmission type Constant-mesh 5-speed Operation Left foot Gear ratio 1st nd rd th th Chassis Frame type Diamond Caster angle 26 Trail 109 mm Tires Front Type Tubeless tire Size 120/70 ZR17 (58 W) Manufacturer/model Metzeler / MEZ4B FRONT Bridgestone / BT020FN Rear Type Tubeless tire Size 180/55 ZR17 (73 W) Manufacturer/model Metzeler / MEZ4J Bridgestone / BT020RN 8 8-2

96 SPECIFICATIONS 8 Maximum load* 208 kg Tire air pressure (measured on cold tires) Up to 90 kg* Front 250 kpa (2.50 kgf/cm 2, 2.50 bar) Rear 250 kpa (2.50 kgf/cm 2, 2.50 bar) 90 kg maximum* Front 250 kpa (2.50 kgf/cm 2, 2.50 bar) Rear 290 kpa (2.90 kgf/cm 2, 2.90 bar) High-speed riding Front 250 kpa (2.50 kgf/cm 2, 2.50 bar) Rear 290 kpa (2.90 kgf/cm 2, 2.90 bar) * Total weight of rider, passenger, cargo and accessories Wheels Front Type Cast wheel Size 17 MT 3.50 Rear Type Cast wheel Size 17 MT 5.50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm (link suspension) Spring/shock absorber Front Coil spring / oil damper Rear Coil spring / gas-oil damper Wheel travel Front 135 mm Rear 125 mm Electrical system Ignition system Transistorized coil ignition (digital) Charging system Type A.C. magneto Standard output 14 V, 490 5,000 r/min Battery Model GT14B-4 Voltage, capacity 12 V, 12 Ah Headlight type Quartz bulb (halogen)

97 SPECIFICATIONS Bulb voltage, wattage quantity Headlight 12 V, 60/55 W 2 Tail/brake light 12 V, 5/21 W 2 Turn signal light 12 V, 21 W 4 Meter lighting 14 V, 1.12 W 4 Neutral indicator light 14 V, 1.12 W 1 High beam indicator light 14 V, 1.12 W 1 Turn signal indicator light 14 V, 1.4 W 2 Engine trouble warning light 14 V, 1.12 W 1 Oil level warning light 14 V, 1.12 W 1 Fuses Main fuse 50 A Fuel injection system fuse 15 A Headlight fuse 25 A Signaling system fuse 15 A Radiator fan fuse 15 A Ignition fuse 10 A Backup fuse (odometer and clock) 10 A Windshield motor fuse 2 A 8 8-4

98 SPECIFICATIONS 8 Conversion table CS-03E EAU03941 All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit values to IMPERIAL unit values. Example: METRIC VALUE CONVERSION FACTOR IMPERIAL VALUE 2 mm = 0.08 in Torque Weight Conversion table METRIC SYSTEM TO IMPERIAL SYSTEM Metric unit Conversion factor Imperial unit m kgf m kgf cm kgf cm kgf kg g ft lb in lb ft lb in lb lb oz Speed km/h mi/h Distance Volume, Capacity Miscellaneous km m m cm mm cc (cm 3 ) cc (cm 3 ) L (liter) L (liter) kgf/mm kgf/cm 2 C mi ft yd in in oz (IMP liq.) cu in qt (IMP liq.) gal (IMP liq.) lb/in psi (lb/in 2 ) F 8-5

99 CONSUMER INFORMATION Identification numbers Key identification number Vehicle identification number Model label Motorcycle noise regulation (for Australia)

100 9-CONSUMER INFORMATION EAU EAU02944 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. KEY IDENTIFICATION NUMBER: CA-02E 2. VEHICLE IDENTIFICATION NUMBER: CA-02E 3. MODEL LABEL INFORMATION: CA-01E 1. Key identification number 1. Vehicle identification number EAU01041 Key identification number The key identification number is stamped into the key tag. Record this number in the space provided and use it for reference when ordering a new key. EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe. Record this number in the space provided. NOTE: The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your area. 9-1

101 1. Model label EAU01804 Model label The model label is affixed to the frame under the rider seat. (See page 3-10 for rider seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer. EAU01388 Motorcycle noise regulation (for Australia) TAMPERING WITH NOISE CON- TROL SYSTEM PROHIBITED: Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b) The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. CONSUMER INFORMATION 9 9-2

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